Experimental study of dual nano-network, high-temperature resistant aerogel material as an integration of thermal management functions

Thermal management system is highly desirable to guarantee the performance and thermal safety of lithium-ion batteries, but it reduces the energy density of battery modules and even is unable to provide highly effective protection. Here, a thermal management function integrated material is presented based on high-temperature resistant aerogel and phase change material and is applied at both charge-discharge process and thermal runaway condition. In this sandwich structure Paraffin@SiC nanowire/Aerogel sheet (denoted as PA@SAS) system, SiC nanowires endow the middle aerogel sheet (SAS) a dual nano-network structure. The enhanced mechanical properties of SAS were studied by compressive tests and dynamic mechanical analysis. Besides, the thermal conductivity of SAS at 600 °C is only 0.042 W/(m K). The surface phase change material layers facilitate temperature uniformity of batteries (surface temperature difference less than 1.82 °C) through latent heat. Moreover, a large-format battery module with four 58 Ah LiNi0.5Co0.2Mn0.3O2 LIBs was assembled, PA@SAS successfully prevents thermal runaway propagation, yielding a temperature gap of 602 °C through the 2 mm-thick cross section. PA@SAS also exhibits excellent performance in other safety issues such as temperature rise rate, flame heat flux, etc. The lightweight property and effective insulation performance achieves significant safety enhancement with mass and volume energy density reduction of only 0.79% and 5.4%, respectively. The originality of the present research stems from the micro and macro structure design of the proposed thermal management material and the combination of intrinsic advantages of every component. This work provides a reliable design of achieving the integration of thermal management functions into an aerogel composite and improves the thermal safety of lithium-ion batteries.